Synthetic rope for powered blocks and methods for production

ABSTRACT

Disclosed is a method for producing a high strength synthetic strength member ( 7 ) containing rope ( 1 ) capable of being used with powered blocks where such rope has lighter weight and similar or greater strength than steel wire strength member containing ropes used with powered blocks. Disclosed also is the product resulting from such method. The product includes a synthetic strength member, a first synthetic portion ( 9 ) and a second synthetic portion. The first synthetic pillion is enclosed within the strength member and the second synthetic portion is situated external the strength member. At least a portion of the second synthetic portion also is situated internal a sheath ( 8 ) formed about the strength member. The second synthetic portion has a minimal of 8% at a temperature of between negative 20 and negative 15° C.

TECHNICAL FIELD

The present disclosure relates generally to the technical field ofsynthetic ropes and, more particularly, to a rope that preferably ismade from synthetic polymeric material, that has a rather high breakingstrength and that also has a rather light weight compared to steel wirerope and that is capable of being used with powered blocks, tractionwinches, powered winches, powered drums, drum winches, powered capstansand in general any powered turning element and/or rotating elementcapable of applying force to a rope (hereinafter aggregately known as“powered blocks”). Such synthetic ropes include but are not limited totow ropes, towing warps, trawl warps (also known as “trawlwarps”), deepsea lowering and lifting ropes, powered block rigged mooring ropes,powered block rigged oil derrick anchoring ropes used with blocks andalso with powered blocks, superwides and paravane lines used in seismicsurveillance including but not limited to used with towed arrays,yachting ropes, rigging ropes for pleasure craft including but notlimited to sail craft, running rigging, powered block rigged anchorropes, drag lines, and the like.

BACKGROUND ART

Due to the high costs of raw materials needed to produce synthetic highstrength ropes such as ropes made from state of the art syntheticmaterials including UHMWPE and others, it is important to increase theboth the longevity as well as the strength that can be obtained fromsynthetic high strength ropes for a given amount of material. In thecase of increased longevity, the increase in longevity is important inorder to reduce replacement costs. Additionally, the increase inlongevity can permit use of lowered diameter and thus lighter and lessexpensive to deploy ropes as in the present state of the art larger thannecessary initial diameters are selected in order to provide for aminimum desired longevity of the rope due to anticipated rates ofdecrease in rope strength and ultimate longevity. In the case ofincreased strength, the increase in strength is important both todecrease costs of raw materials and production process, costs of riggingequipment needed to carry, lift, stabilize and stably float and/orotherwise sustain and support the weight of the ropes, as well todecrease drag in water and drag in air of such ropes. In the environmentof winches, drums and traction winches, i.e. powered blocks, it isespecially important to make such ropes more readily usable on suchpowered blocks. Furthermore, it is important to increase the lifeexpectancy of such ropes in order to obtain the greatest economicadvantage from a given investment in any such rope.

While attempts and methods of adhering a steel wire rope's strengthmember to a sheath surrounding a steel strength member have failed inincreasing the steel wire ropes strength, and actually reduce the steelwire rope's strength for a given diameter (a rope's strength necessarilymeasured in relation to its diameter) such attempts and methods havesucceeding in increasing the longevity of certain steel wire ropes.However, in the case of ropes formed with synthetic and/or mainlysynthetic strength members, all known attempts to increase the strengthand/or the longevity of synthetic ropes by adhering a sheath surroundinga strength member to the synthetic and/or mainly synthetic strengthmember have failed to increase either the strength of the rope or itslongevity, and in fact do the opposite. That is, known methods ofadhering a synthetic rope's strength member to a sheath surrounding suchstrength member actually decrease both the strength and longevity of theropes. For this reason, such known constructions increase not only theexpense of the rope, but also its diameter and thus associated drags infor example water, as well as its weight and thus associated costs forstructures affixing, floating, sustaining or otherwise supporting suchropes. As a consequence, it is contrary to the trend in the industry andagainst the state of the art to adhere to a synthetic rope's strengthmember a sheath surrounding such strength member.

As another consequence, it is accurate to state that it is contrary tothe trend in the industry and against the state of the art to actuallyimprove a rope's strength by adhering a sheath to the ropes strengthmember, especially by adhering a sheath to a synthetic and/or mainlysynthetic ropes synthetic and/or mainly synthetic strength member, andthat such result would be surprising to those skilled in the art.

In the present state of the art, when forming high strength syntheticstrength members for use in forming a high strength rope, the strongestsynthetic fiber available at a certain price point and suitable for acertain environment of intended deployment is used. It is well knownthat synthetic high strength ropes have a drawback of being veryexpensive. Furthermore, synthetic high strength ropes are prone to amuch more rapid rate of degradation than natural, e.g. wire ropes, andare quicker to experience abrasion induced failure when used on poweredblocks, whether in protected environments or in high temperature andabrasive environments, as opposed to when such synthetic high strengthropes are used in static applications. However, due to their relativelylight weights and also due to their relative low diameters for a givenstrength, and also due to their ability to not rust or oxidize in airand humid environments at an appreciable rate compared to metal fibreropes, state of the art high strength synthetic ropes, such as ropesmade from Vectran®, Zylon® (i.e. PBO), Carbon fibers, Aramids and thelike are highly desirable in many applications where light weights andminimal diameters are desired in order to minimize structural loads, toenhance aesthetic appearance such as in pleasure yachting, to minimizethe costs of structures to which the ropes affix, and also where lowdrags are desired such as in towed applications and mooringapplications, the relatively low diameters of such synthetic highstrength ropes providing for lowered drags compared to other ropes. Thepresent state of the art and the current trend in the industry is thatsuch ropes either do not include a sheath about their synthetic strengthmember, or that if they do include a sheath that no attempt is made andno construction is provided to adhere the sheath and the strength memberto one another. This is because, as mentioned above, known constructionsand methods for adhering a synthetic strength member to a sheathsurrounding such strength member actually decrease the strength of aswell as decrease the longevity of known synthetic ropes, includingsynthetic ropes for use with powered blocks.

Ropes having sheaths such as plastic sheaths surrounding a strengthmember, and ropes having synthetic barriers including adhesives andthermoplastics between a strength member and a sheath have failed to besuccessfully used with powered blocks, whether such ropes are syntheticor natural ropes, and the present state of the art and the current trendin the industry is that natural as well as synthetic strength membersused with powered blocks have no such type of sheath, as the cost offorming such sheaths has not been proved to be of benefit. It isunderstood in the industry that a sheath is not a primary strengthbearing unit of a rope, whether a natural or a synthetic rope, butrather that a strength member is the primary strength bearing unitforming a rope. Nonetheless, due to the advantages of lightness ofweight that high strength synthetic strength member ropes offer,attempts continue to be made to successfully deploy into industry on awide scale high strength synthetic strength member ropes for use withpowered blocks, such attempts including forming a sheath formed ofbraided strands about such high strength synthetic strength members inattempt to increase the longevity and thus reduce the long terminvestment associated with using high strength synthetic ropes. However,the very high costs of such high strength synthetic strength membercontaining ropes compared to natural high strength ropes, e.g. wireropes, and the fact that such high strength synthetic strength membercontaining ropes when used with powered blocks experience rather fastdeterioration of their sheaths and ultimately of the synthetic strengthmembers, has resulted in the fact that today only limited marketacceptance has been gained for high strength synthetic strength membercontaining ropes for use with powered blocks. That is, known highstrength synthetic strength member containing ropes used with poweredblocks are known for rather quickly experiencing abrasion inducedfailure, and for experiencing a rather rapid strength degradation priorto absolute failure for their cost. Due to the extremely high cost ofsuch ropes, their premature failure and short life spans when used withpowered blocks, the adoption of high strength synthetic strength memberropes for use with powered blocks has been limited. For example, thevast majority of the world's trawlers even in highly developed regionscontinue to use wire rope as trawl warps, despite the great weight andsafety concerns caused by such weight when the natural high strengthrope is stored on a trawl winch—i.e. vessel instability, it being wellknown that the weight of such stored wire trawling warps has often beenimplicated in vessel capsize. Thus, a long felt need continues to existin the industry for a high strength synthetic strength member containingrope capable of being used with powered blocks that has improvedlongevity, including improved strength retention over time. Thus also,it can be appreciated that a long felt need continues to exist in theindustry for a high strength synthetic strength member containing ropecapable of being used with powered blocks that has improved strength.

Published Patent Cooperation Treaty (PCT) International PublicationNumber WO 2004020732 A2, International Application NumberPCT/IS2003/000025 discloses a cable having a thermoplastic core within abraided synthetic strength member. The cable is a heat stretched cableexhibiting ultra compactness and is useful for high tension poweredblock applications. In one embodiment, disclosed is a cable wherein thematerial of the thermoplastic core contacts both the synthetic strengthmember and a braided synthetic sheath formed about the outside of thestrength member. However, this embodiment has failed to be commerciallyaccepted for the reasons taught above, i.e. due to the fact that thestrength of the cable is reduced by such construction.

In all embodiments, it is taught that the heat stretching and compactingof the cable is accomplished either by simultaneously heating andstretching with tension the combination of the strength member, thethermoplastic core and a second sheath formed about the thermoplasticcore and also contained within the strength member, the purpose of suchsecond sheath being to prevent uncontrolled flow of molten phase of thethermoplastic core during processing of the rope, or by first applyingthe heat and subsequently applying the tension. This cable has foundmore commercial acceptance than any other synthetic rope for use withhigh tension powered blocks, and is the only viable synthetic rope inthe known art for use with high tension powered blocks such as trawlerwinches for purposes such as trawl warps, and this cable and its taughtmanufacturing processes represent both the state of the art as well asthe trend in the industry.

DISCLOSURE

It is an object of the present disclosure to provide for a high strengthsynthetic strength member containing rope for use with powered blocksthat addresses the above stated long felt need in the industry.

It is an object of the present disclosure to provide for a high strengthsynthetic strength member containing rope capable of being used withpowered blocks that exhibits improved strength.

It is another object of the present disclosure to provide for a highstrength synthetic strength member containing rope capable of being usedwith powered blocks that exhibits improved strength retention over timeand thus improved longevity.

It is yet another object of the present disclosure to provide for a highstrength synthetic strength member containing rope capable of being usedwith powered blocks that exhibits both improved strength as well asimproved strength retention over time and improved longevity.

It is yet another object of the present disclosure to provide for a highstrength synthetic strength member containing rope capable of being usedwith powered blocks and satisfying the above stated objects of thepresent disclosure where such rope is capable of being used insubstitution of steel wire strength member containing ropes forapplications including but not limited to trawl warps, anchoring lines,seismic lines, oil derrick anchoring and mooring lines, tow ropes,towing warps, deep sea lowering and lifting ropes, powered block riggedmooring ropes, powered block rigged oil derrick anchoring ropes usedwith blocks and also with powered blocks, superwides and paravane linesused in seismic surveillance including but not limited to used withtowed arrays, yachting ropes, rigging ropes for pleasure craft includingbut not limited to sail craft, running rigging, powered block riggedanchor ropes, drag lines, climbing ropes, pulling lines and the like.

Disclosed is a method for producing a high strength synthetic strengthmember containing rope capable of being used with powered blocks wheresuch rope has lighter weight and similar or greater strength than steelwire strength member containing ropes used with powered blocks.Disclosed also is the product resulting from such method. Most broadly,the product includes a synthetic strength member, a first syntheticportion and a second synthetic portion, where the first syntheticportion is enclosed within the strength member and/or mainly is enclosedwithin the strength member and the second synthetic portion is situatedexternal the strength member and/or mainly is situated external thestrength member, at least a portion of the second synthetic portion alsobeing situated internal a sheath formed about the strength member, thefirst and second synthetic portions having differing elasticity values,the second synthetic portion having greater elasticity than the firstsynthetic portion. Preferably, the elasticity of the second syntheticportion is in a range of elasticity values as taught herein as usefulfor an adhesive substance capable of adhering the strength member to thesheath, with a range of elasticity of from twenty percent (20%) to fivehundred fifty percent (550%) measured at any temperature, within two (2)degrees Centigrade of zero (0) degrees Centigrade, being preferred, suchas preferably at zero degrees Centigrade.

In a most preferred embodiment, an additional synthetic substance issituated and/or mainly situated about and between fibres forming thestrength member, the additional synthetic substance capable of being anadhesive substance that adheres one to another various fibres formingthe strength member and also preferably has an elasticity that is lesserthan the elasticity of the second synthetic portion.

Most broadly, the method for producing the high strength synthetic ropecapable of being used with powered blocks is characterized by the stepsof:

a) providing a core capable of supporting a hollow strength member andcapable of fitting within an internal cavity formed by the hollowstrength member, this core forming the first synthetic portion;

b) forming a synthetic strength member about the core;

c) situating about the outside of the strength member a substancecapable of being, during at least one of its phases, a substance capableof adhering a substance forming the strength member to a substanceforming a sheath, the sheath preferably being a braided sheath formed ofstrands formed of synthetic fibres; and

d) forming the sheath about the outside of both the strength member andthe substance capable of being, during at least one of its phases, asubstance capable of adhering the substance forming the strength memberto the substance forming the sheath, where the substance capable ofadhering the substance forming the strength member to the substanceforming the sheath has an elasticity that is greater than the elasticityof the core, and that preferably is in the range of elasticity values astaught herein as useful for an adhesive substance capable of adheringthe strength member to the sheath, with a range of elasticity of fromtwenty percent (20%) to five hundred fifty percent (550%) measured atany temperature, within two (2) degrees Centigrade of zero (0) degreesCentigrade being preferred, such as preferably at zero degreesCentigrade.

The substance capable of being, during at least one of its phases, asubstance capable of adhering a substance forming the strength member toa substance forming the sheath, forms the second synthetic portion ofthe rope of the present disclosure.

Most preferably, the method includes the additional step of includingabout and between fibres forming the strength member a third syntheticsubstance where such third synthetic substance is capable of adheringone to another various fibres forming the strength member, such thirdsynthetic substance having an elasticity that is lesser than theelasticity of the second synthetic substance.

Due to the disclosed synthetic rope for use with powered blocks lightweight compared to steel wire cable coupled with its improved strength,improved strength retention over time and improved longevity, itpossesses the advantages of being more buoyant in water than steel wirecable while also being capable of enduring the rigors of use in any ofthe mentioned applications of use for a longer duration than steel wirecable.

Another advantage of the disclosed synthetic rope for powered blocks isthat it permits dramatically reduced superstructures and associatedcosts for floating mooring andor anchor lines needed to anchor oilderricks, especially deep water oil derricks and other floatingstructures.

Yet another advantage of the disclosed synthetic rope for powered blocksis that due to its increased strength less of the rope is required andthus less weight is required to be stored on for example trawler drums,and thus it lowers the center of buoyancy of trawlers using thedisclosed rope for trawl warps thereby improving trawler safety.

Yet another advantage of the disclosed synthetic rope for powered blocksis that due to its increased strength less of the rope is required andthus it has a lowered diameter per application requirement, therebyconcurrently reducing drags in water and fuel consumption costsassociated with pertinent applications including but not limited totrawl warps, superwides and paravane lines, seismic lines anchor lines,deep water oil derrick mooting andor anchoring lines, drag lines andothers as a result of the increased strength of the disclosed rope.

Yet another advantage of the disclosed synthetic rope for powered blocksis that due to its increased strength less of the rope is required andthus it has a lowered diameter per application requirement, therebyreducing costs to produce and acquire the rope.

Possessing the preceding advantages, the disclosed synthetic rope forpowered blocks answers needs long felt in the industry.

It can readily be appreciated that these and other features, objects andadvantages are able to be understood or apparent to those of ordinaryskill in the art from the following detailed description of thepreferred embodiment as illustrated in the various drawing figures.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a plan view of a portion of a rope of the present disclosure.

FIG. 2 is a view of a cross section of the rope of the presentdisclosure taken along line A-A FIG. 1.

FIG. 3 is an expanded detail view of a portion of the cross section ofthe rope of the present disclosure shown in FIG. 2 that is indicated byreference character B. The expanded detailed view includes a braidedsheath of the rope of the present disclosure, a portion of the strengthmember of the rope of the present disclosure where such portion of thestrength member is proximal the braided sheath, as well as associatedstructures.

Figure legend: 1—Synthetic Rope of the Present Disclosure

-   -   2—Lead Core    -   3—Shaped Supportive (Thermoplastic) Core    -   5—Flow Shield Sheath    -   7—Strength Member    -   9—Elastic Adhesive Substance Layer    -   10—Coverbraid Strands    -   13—Elastic Adhesive Substance Gap Filling Surface Layer

BEST MODE FOR CARRYING OUT THE DISCLOSURE

FIG. 2 and FIG. 3 illustrate essential constructional components of oneof the most preferred embodiments for use with high tension poweredblocks of the rope for powered blocks and winches of the presentdisclosure that is identified by the general reference character 1. FIG.2 depicts a preferably thermoplastic shaped supportive core 3 enclosinga lead core 2, the shaped supportive core 3 being enveloped within aflow shield sheath 5. Strength member 7 encloses the combination of theshaped supportive core 3, its enveloping flow shield sheath 5 and itslead core 2. Sheath 8 preferably is of a braided construction and isadhered to strength member 7 by elastic adhesive substance layer 9, thatpreferably is formed of a settable adhesive substance. Preferablybraided sheath 8 is formed of multiple coverbraid strands 10 by use of abraiding machine, the coverbraid strands 10 preferably are of a laidconstruction. Optionally, and preferably, as shown in more easilyvisible detail in FIG. 3, elastic adhesive substance gap filling surfacelayer 13 fills in depressions on the surface of rope 1 formed in betweenadjacent coverbraid strands 10. Lead core 2 is optional, and ispreferred for trawl warp applications and in the case of certain otherapplications, but not necessarily in the case of anchor lines and deepwater oil derrick mooring and/or anchoring lines or yachting lines,although in some cases it may be used in such applications.

Shaped supportive core 3 also defines the first synthetic portion of therope of the present disclosure mentioned above, and elastic adhesivesubstance layer 9 also defines the second synthetic portion of the ropeof the present disclosure as mentioned above.

The present disclosure is based upon the surprising and shockingdiscovery that both the strength, the strength retention over time of aswell as the longevity of a synthetic high strength rope can bematerially increased by adhering to the outside surface of a syntheticstrength member a sheath and preferably a tightly braided sheath by useof an adhesive substance exhibiting when in its final, set phase anelasticity of greater than eight percent (8%) when the final set phaseof the adhesive substance is measured at any temperature in atemperature range including from negative twenty (−20) degreesCentigrade to negative fifteen (−15) degrees Centigrade. Such result isshocking and surprising because it is contrary to the trend in theindustry and against the state of the art. An adhesive substanceexhibiting the greater than 8% (eight percent) elasticity at suchtemperature range also provides for a rope exhibiting the improvedstrength, improved strength retention over time as well as exhibitingthe improved longevity at higher temperatures, and at lowertemperatures, even temperatures exceeding seventy (seventy) degreesCentigrade and also even temperatures lower than negative twenty (−20)degrees Centigrade.

In a preferred embodiment of the present disclosure, the adhesivesubstance exhibits when in its final, set phase an elasticity preferablyof greater than ten point one percent (10.1%) when the final set phaseof the adhesive substance is measured at a temperature range includingfrom negative fifteen (−15) degrees Centigrade to negative five (5)degrees Centigrade. An adhesive substance exhibiting the greater than10.1% (ten point one percent) elasticity at such temperature range alsoprovides for a rope exhibiting the improved strength, improved strengthretention over time as well as exhibiting the improved longevity athigher temperatures, and at lower temperatures, even temperaturesexceeding seventy (seventy) degrees Centigrade and also eventemperatures lower than negative twenty (−25) degrees Centigrade. In aneven yet more preferred embodiment the elasticity is preferably at leasttwenty percent (20%) when measured at any temperature within the abovestated temperature range of from negative fifteen (45) degreesCentigrade to negative five (−5) degrees Centigrade, and even morepreferably at least fifty percent (50%) at such temperature range, yetmore preferably at least eighty percent (80%) at such temperature range,and yet even more preferably at least one hundred percent (100%) at suchtemperature range and where the adhesive substance also is capable ofexhibiting an elasticity of greater than twenty percent (20%) attemperatures in a range of from room temperature (i.e. twenty-fivedegrees Centigrade) up to and exceeding forty (40) degrees Centigrade,with an elasticity measured at room temperature of fifty-two percent(52%) to five hundred fifty percent (550%) being preferred and with anelasticity of from one hundred percent (100%) to five hundred fiftypercent (550%) or even greater when measured at room temperature beingmost preferred.

A preferred adhesive substance is one that contains an elastomer orelastomer like substance, and/or an elastomer containing substance, suchas a solid elastomer-like polyurethane based upon two, three or morecomponent isocyanate polymer blends and especially with additives andcuratives. As taught in further detail herein, the rope of the presentdisclosure preferably has its primary strength member formed of UHMWPEand/or LCP and/or PBO. An most preferred adhesive substance for adheringthe strength member to the sheath is an adhesive substance having at atemperature that is within two (2) degrees of zero (0) degreesCentigrade a minimal elasticity of greater than 20%, preferably ofgreater than 50%, even more preferably of greater than 100%, greaterthan 200%, greater than 300%, greater than 400% and greater than 500%.In general, the greater the elasticity of the adhesive substance overand above 20% at such temperature range, the greater the longevity ofthe disclosed rope.

Other examples of suitable adhesive substances include silicone,including pure (100%) silicone, as well as a substance that can be madeby combining substances known in the industry as “hot melts” withsufficient elastomer and/or elastomeric substances so as to result in ahighly elastic hot melt type substance exhibiting the above taughtelasticity values at the above taught temperature ranges.

For purposes of the present disclosure, a rope and/or a portion of arope is considered to be at the above taught temperature ranges, or at acertain temperature range and an elastic substance is considered to beat the above taught temperatures and/or temperature range when such ropeand/or elastic substance has been continuously exposed to suchtemperature range for at least 24 hours. For example, continuouslyexposed to a temperature of from negative fifteen (−15) degreesCentigrade to negative twenty (−20) degrees Centigrade for a period oftime that is at least 24 hours, and when the elastic substance beingtested for elasticity, rope and/or portion of rope being tested for itselastic substances elasticity actually is at such temperature range.

As taught supra, a rope having a strength member, and preferably asynthetic strength member, adhered to a sheath and preferably to asynthetic sheath by use of an elastic material exhibiting the abovetaught elasticity at the above taught temperatures is surprisingly andshockingly able to exhibit both improved strength, improved strengthretention over time as well as improved longevity, including improveddurability, at a wide range of temperatures including temperatures frombut not limited to even temperatures exceeding seventy (seventy) degreesCentigrade and also even temperatures lower than negative twenty (−20)degrees Centigrade, depending largely upon the ability of filamentsforming synthetic portions of the rope of the instant disclosure totolerate a certain temperature.

In order to form the rope of the present disclosure:

In another embodiment a rope of the present disclosure is able to beformed by situating upon the outside surface of a strength member a filmor other coating of an adhesive substance having an elasticitypreferably of at least 20% when measured at a temperature range ofincluding but not limited to from at least zero degrees Centigrade to atleast ten degrees Centigrade, subsequently tightly braiding a braidedsheath (including braided cover) about the combination of the strengthmember and the film or other coating of such adhesive substance, thencausing and/or permitting the adhesive substance to set (includingcure).

In yet another embodiment a rope of the present disclosure is able to beformed by situating upon the outside surface of a strength member abraided, laid and/or wrapped layer of filaments formed of a substancethat is itself formed of a combination of hot melt and sufficientelastomer and/or elastomeric substance so as to permit, when elastomercontaining hot melt substance is in a set phase, the elasticityproperties at the temperature ranges as taught herein. In suchembodiment of the present disclosure: first a strength member is formed;then the filaments are situated upon the outside of the strength member;then the sheath is formed about the combination of the filaments and thestrength member; then the combination of the strength member, filamentsand sheath are subjected to a predetermined tension and temperature perthe fifth and sixth steps described supra for forming a rope of thepresent disclosure according to the presently most preferred manufacturemethod.

To further describe such embodiment: preferably a settable adhesivesubstance is situated upon the outside surface of the strength member,then a braided sheath is tightly braided about the combination of thestrength member and the settable adhesive substance, then the settableadhesive substance is allowed to set (including cure). In forming therope of the present disclosure by the method of this embodiment,preferably the settable adhesive substance is situated upon the outsidesurface of the strength member in such a fashion that and/or underconditions that preclude the adhesive substance to set until at leastthat portion of the sheath corresponding to any particular portion ofthe combination of the strength member and the settable adhesivesubstance has already been formed about the combination of the strengthmember and the film or other coating of settable adhesive substance. Inother words, preferably the settable adhesive substance and/or theconditions under which it is situated upon the outside surface of thestrength member, such as temperature, is/are selected so that thesettable adhesive substance sets and/or completely sets only after thesheath has been formed about the outside surface of the strength member,causing the sheath to adhere to the strength member.

To form the rope of the present disclosure by another embodiment of thepresent disclosure, an adhesive substance including but not limited toeither an already set adhesive substance applied to the outside surfaceof the strength member as powder, a fluid permitted to set, a tape orother wrapping is caused to set prior to forming a sheath about thestrength member, or a settable adhesive substance that sets after thesheath is formed about the strength member is/are situated upon theoutside surface of the strength member. Next, a braided sheath istightly braided about the outside surface of the strength member usingknown methods and preferably from filaments formed and/or mainly formedof the same material as filaments forming the strength member. Then, thecombination of the strength member, the adhesive substance situated uponthe outside surface of the strength member and the preferably braidedsheath formed about the combination of the strength member and theadhesive substance situated on the outside surface of the strengthmember are heated and/or exposed to radiation, such as microwaveradiation, and/or exposed to another catalyst that causes the adhesivesubstance to undergo a phase change, especially from solid to a liquidstate, or from an non-adhesive to an adhesive state, and then theadhesive substance is caused to set, thereby adhering the strengthmember to the sheath by the adhesive substance, the adhesive substanceselected so as to have the elasticity properties for a preferredadhesive substance for practicing the instant disclosure as disclosedherein.

Thus, in forming a rope of the present disclosure, a synthetic rope isformed of a strength member and a braided sheath, the strength memberand the braided sheath both formed of synthetic material, the syntheticrope having:

a synthetic substance filling out void spaces between the strengthmember and the braided sheath and causing adherence of the strengthmember to the braided sheath, where the synthetic substance exhibitswhen in a set phase and when at a temperature of:

a) between negative twenty and negative fifteen degrees Centigrade aminimal elasticity of greater than 8%;

b) between negative fifteen and negative five degrees Centigrade aminimal elasticity of greater than 10.1%; and

c) between negative fifteen and zero degrees Centigrade a minimalelasticity of greater than 20%.

Furthermore, other elasticity values exhibited at other temperatures, astaught herein, are useful for the synthetic substance that causesadherence of the strength member to the braided sheath.

Importantly, it is surprisingly and shockingly discovered that tomaximize both longevity as well as strength of the rope of the presentdisclosure the synthetic strength member preferably includes a chemicalagent contacting the filaments forming the strength member and/or beingsituated between filaments forming the strength member and/or alsoincluding being situated upon the outside surface of the strength memberwhere such chemical agent has a lower elasticity than the elasticityselected for the adhesive substance that adheres a braided sheath to theoutside surface of the strength member (for the purposes of the presentdisclosure, comparative elasticity values are measured at temperaturethat is between negative zero degrees Centigrade and 10 degreesCentigrade). Such chemical agent may itself be an adhesive agent. Thesettable adhesive substance preferably is situated upon the outsidesurface of the strength member as a liquid or as a semi-liquid, theterms “liquid” and “semi-liquid” as used in the present disclosure bothalso known as “in a flowable state”. This includes that the settableadhesive substance may also be situated around, about, so as to envelopor so as to be directly upon the strength member including a strengthmember having additional chemicals including additional adhesives uponand in between its filaments and/or any other chemical or mechanicalbarrier upon its outside surface and/or any adhesive substance or othersubstance upon its outside surface to which the settable adhesive isable to adhere. The braided sheath is then formed about the combinationof the strength member and the coating while the substance forming thecoating is still liquid and/or semi-liquid (including “flowable”). Theset time, also known as the lag time, within which the settable adhesivesubstance shall set is selected so that during the process of braidingthe braided sheath about the strength member the strands forming thebraided sheath are adhered to the strength member. Void spaces normallybetween the strength member and the braided sheath are filled by thesettable adhesive substance, and in some preferred embodiments thethickness of the coating, the braiding angle as well as the lag time ofthe settable adhesive substance are selected so that the settableadhesive substance first is situated upon the outside surface of thestrength member, then the braided sheath is braided about the strengthmember causing the settable adhesive substance both to occupy voidspaces between the braided sheath and the strength member as well as toflow between the strands of the braided sheath to the outside surface ofthe braided sheath, especially during the convergence of such strands ator about the braid point, and remain on the outside surface of thebraided sheath. In this case, the method of the present disclosureincludes smoothing the settable adhesive substance on and about theoutside surface of the braided sheath so that the settable adhesivesubstance acquires a smooth surface and preferably a generallyaesthetically attractive surface.

However, in this embodiment, the amount of the settable adhesivesubstance that is able to flow between the strands is largely related tothe viscosity selected for the settable adhesive substance. When arelatively low viscosity is selected, the settable adhesive substance isable to more readily flow between the strands of the braided sheath. Oneof ordinary skill in the art having read the present disclosure shall byexperimentation be able to readily determine the ideal viscosity for anyparticular settable adhesive substance, and such experimentallydetermined values for a viscosity for any particular settable adhesivesubstance is intended to be encompassed within the scope of theteachings of the present disclosure. When a viscosity is selected forthe settable adhesive substance that precludes sufficient of suchsettable adhesive substance to flow between the converging strands ofthe braided sheath so as to result in a pre-determined amount of thesettable adhesive substance becoming situated upon the outside surfaceof the braided sheath, an additional amount of the settable adhesivesubstance may be situated directly upon the outside surface of thebraided sheath. Such settable adhesive substance may be situateddirectly upon the outside surface of the braided sheath by:

a) first passing the rope of the present disclosure with the braidedsheath already formed upon the strength member through a bath of aselected settable adhesive substance, and then either:

i) allowing such settable adhesive substance to dry, as is suitable whenthe viscosity of the settable adhesive substance is sufficiently high soas to allow the settable adhesive substance to acquire an even and/oruniform distribution on and about the outside surface of the braidedsheath without further manipulation; or

ii) when a relatively high viscosity is selected for the settableadhesive substance, it is preferred to pass the rope having been bathedin the selected settable adhesive substance through a die that isdesigned, shaped and configured so as to smooth the settable adhesivesubstance into a desired shape upon the outside surface of the rope ofthe present disclosure, preferably a circular cross sectional shape, andincluding into a desired thickness.

Preferably, when the settable adhesive substance is situated upon theoutside surface of the braided sheath, the thickness of the layer of thesettable adhesive substance on and about the outside surface of thebraided sheath is such as to occupy depressions (i.e. valleys) betweenthe strands of the braided sheath, while either not covering, or whilelightly covering high points (i.e. peaks) formed by the strands of thebraided sheath. In one embodiment, such high points, i.e. peaks, arevisible, while the valleys are filled with the settable adhesivesubstance, as is accomplished by the fact that after some initial wearand surface abrasion any settable adhesive substance present on thepeaks is rubbed off, leaving the settable adhesive substance that islocated in the valleys. During use, as the rope of the presentdisclosure is bend over a radius, the compressed side of the bent ropecompresses the valley walls, whereby the portion of settable adhesivesubstance within the valley walls is partially bulged outward where itis able to grip and provide additional traction to the surface upon andabout which the rope is being bent.

Importantly, surprisingly, shockingly and contrary to the state of theart and the trend in the industry, in order to obtain both maximalstrength as well as maximal strength over time (i.e. longevity) from therope of the instant disclosure, the strength member is formed offilaments and/or includes filaments that are able to be creeped. Forexample, filaments are selected that are able to be permanentlyelongated upon being heated to a temperature approaching or at the phasechange temperature of a chemical mainly forming the filaments.Surprisingly, shockingly and contrary to the state of the art that is toemploy maximally strong filaments such as Vectran®, Zylon® and otherswhen forming high strength ropes, it has been found that filamentshaving a lesser strength than such maximally strong filaments, but ableto be creeped as taught above, are highly preferably for forming amaximally strong rope of the present disclosure. In fact, surprisingly,shockingly and contrary to the state of the art, a rope of the instantdisclosure formed of filaments that are able to be creeped as taughtherein, for example filaments formed of UHMWPE, is stronger than a ropeformed of stronger and coincidentally more expensive filaments that arenot able to be creeped, whether such rope formed of stronger andcoincidentally more expensive filaments not able to be creeped is formedby known methods and constructions or by the method and construction ofthe present disclosure.

Preferred Fabrication Methods

There are two preferred embodiments of the present disclosure: one is arope of the present disclosure for use in applications where the rope ofthe present disclosure is subject to storage under high compressivepressure, such as when used with high tension winches and drums, such aswhen used as a trawler's warp; another is where the rope of the presentdisclosure is not subject to storage under high compressive pressure,such as is common in many yachting applications.

In forming a preferred embodiment of the present disclosure for use inapplications where the rope of the present disclosure is subject tostorage under high compressive pressure:

First is provided a strength member formed of synthetic fibres includingpolyethylene, especially HMWPE, UHMWPE and Liquid Crystal Polymer (LCP).The strength member may be parallel laid, laid (including twisted) orbraided. A braided strength member having several strands formed oftwisted (laid) filaments is the preferred embodiment. For example abraided strength member having a minimum of eight plates, preferably tenstrands, more preferably twelve strands, yet more preferably 14 strandand yet more preferably from 16 strands to 108 strands or even more asthe diameter of the rope requires, is preferred. Any conventionalconstruction type for a braided strength member may be used. However, itis highly preferably and important for a preferred embodiment of theinstant disclosure that a braided strength member is selected that has athermoplastic core shaped so as to support the natural interior shape ofthe braided strength member under tension approaching breaking strengthof the strength member. Preferably, for a strength member is provided abraided strength member where the filaments forming the strength memberhave been creeped after the filaments have been braided into thestrength member, rather than prior to braiding the filaments into thestrength member, and where the resultant strength member is unable toelongate greater than 5% before reaching break point when measured at aoriginal tension of 1000 Kg, and preferably so that the resultantstrength member is unable to elongate greater than 4% before reachingbreak point when measured at a original tension of 1000 Kg, and yet morepreferably is unable to elongate more than 3.6% before reaching breakpoint when measured at a original tension of 1000 Kg.

In forming a strength member for the preferred form of the instantdisclosure the following step are employed:

First; filaments are selected that are able to be creeped as taughtabove and herein.

Second; a thermoplastic linear element is provided that is formed with athermoplastic that shall be in a liquid state but more preferably thatshall be semi-liquid, i.e. in a molten phase when such thermoplastic isat a temperature that either is:

a) a temperature that is slightly below, say one, two, three, four,five, six, or seven degrees Centigrade below a temperature at which theselected filaments experience a phase change; or

b) a temperature that is a temperature at which the selected filamentsexperience a phase change.

The thermoplastic linear element is preferably a rod formed ofthermoplastic (the term “formed of thermoplastic” is understood toinclude being formed of a sufficient quotient of thermoplastic so as topermit the linear element to experience the semi-liquid, i.e. moltenphase during the circumstances taught supra and herein, even thoughother substances might be included with the thermoplastic, or even leador other metal or heavy plastic might be included in linear arrangementwithin the center of the thermoplastic linear element that preferably isa rod, so as to increase weight in water of the final product rope ofthe present disclosure).

Third; a tightly woven braided flow-shield sheath is braided around thethermoplastic rod. Filaments are selected to form the flow-shield sheaththat are not made either liquid or semi-liquid at a temperature selectedto either or both creep the filaments or change the phase of either thefilaments or the thermoplastic rod, but rather that have a much highersoftening point. Polyester is suitable.

Fourth; the selected filaments are braided around the linear elementformed of a thermoplastic and its flow-shield sheath, such as athermoplastic rod surrounded by a flow-shield sheath, so as to form abraided strength member including a thermoplastic core surrounded by aflow-shield sheath.

Fifth; the braided strength member having the thermoplastic rodsurrounded by the flow-shield sheath as its core is then subject firstto tension and secondly to heat, while maintaining the tension, in sucha fashion and under such conditions that the filaments forming thebraided strength member either reach their phase change temperature orapproach sufficiently closely to their phase change temperature so as topermit creeping of the filaments. I.e. so as to permit permanentlyelongating both the filaments forming the strength member, as well so asto permit permanently elongating the strength member itself. Athermoplastic is selected to form the thermoplastic core that shallpreferably become semi-liquid, i.e. molten, at the temperature used topermanently elongate the filaments and braided strength member formed ofthe filaments. The flow shield-sheath mainly or entirely stops the phasechanged thermoplastic core from exiting the flow-shield sheath. That is,the majority of the thermoplastic core is unable to exit the flow-shieldsheath even when the thermoplastic core is either liquid or semi-liquid,i.e. molten, despite enormous constrictive and compressive forcesapplied to the phase changed thermoplastic core as a result of the hightensions applied to the strength member, such high tensions able topermanently elongate the strength member under the conditions taughtsupra and herein.

Applying the tension before applying the heat while then maintaining thetension while the heat is being applied is, in combination, contrary tothe trend in the industry and against the state of the art. A preferredtension to be used in the disclosed processes for forming the disclosedrope is about three percent (3%) to about fifteen percent (15%) of thebreak strength of the strength member when such break strength ismeasured at room temperature, with about three percent (3%) to aboutseven percent (7) being preferred, and with less than fifty percent(50%) being most important.

Importantly, the tension applied to the strength member, and thusnecessarily also applied to the filaments forming the strength member,preferably is a static tension and/or a generally static tension and/ora very slowly fluctuating tension. After applying a predeterminedtension (including approximately a predetermined tension), and whileunder such predetermined tension simultaneously the strength member, itsfilaments, and its thermoplastic core are heated to a predeterminedtemperature and/or to approximately a predetermined temperature astaught above and herein, with a minimum temperature of eighty (80)degrees Centigrade being most preferred, and temperatures that approachthe phase change temperature of whatever filament in the strength memberhas a lowest phase change temperature being highly useful. The use of along oven having many capstans able to accommodate a very long length ofthe strength member and turning at varying speeds and/or rates ofrotation so as to maintain the tension on differing portions of thestrength member located between different capstans, and thus byextension on the filaments forming the strength member as well as on thethermoplastic core also forming the strength member is highly useful,especially for permitting an endless flow production process.

Sixth; when the filaments and thus by extension the braided strengthmember have been elongated to a predetermined amount so as to permit astrength member having the properties described above and herein, andespecially having an elongation to break point within the range ofvalues as taught above and herein, and also the thermoplastic core hasbeen elongated, the elongated filaments, the now elongated strengthmember formed of the elongated filaments and its elongated thermoplasticcore are cooled while sufficient tension is maintained and applied tothe strength member and thus by extension to its filaments and to itsthermoplastic core during the cooling process so that all suchcomponents are cooled to their respective solid states while under atension that results in the cooled filaments as well as the cooledstrength member having been permanently elongated so as to cause thestrength member:

a) to acquire a lower elongation than it had prior to its having beenpermanently elongated;

b) to acquire a substantially lesser diameter and a greater compactnessthan it had prior to its having been permanently elongated;

c) to acquire to its thermoplastic content core a permanent solid shapethat supports the interior cavity of the permanently elongated strengthmember in such a fashion that the filaments and braid strands formingthe strength member are sufficiently less able to move relative to oneanother in a direction perpendicular to the long dimension of thepermanently elongated strength member in comparison to prior to thestrength member having been permanently elongated so as to reducefilament to filament abrasive wear, and also so as to preclude crushingof the rope, especially under high compressive forces such as occursduring winding and storage on a high tension drum, the necessary tensionto achieve such result for any particular filament type able to beexperimentally determined by one of ordinary skill in the art afterhaving read the present disclosure; and also

d) to acquire a break point that is within the range of values ofelongation to break point as taught above and herein.

This cooling also is best accomplished and undertaken using capstansturning at varying speeds so as to maintain a tension on the elongatedstrength member and its components during the entire cooling process andperiod that precludes their shortening, so that the final cooledstrength member has the values of elongation to break point as taughtabove and herein for a most preferred embodiment of the instantdisclosure, and also the other properties taught as above and herein, asalso is accomplishable in an endless flow production method.

In order to form a rope of the instant disclosure that is not useful forapplications requiring tolerating high compressive pressures, such asapplications not including a trawler's warp, and other applications notincluding storage of the rope of the present disclosure on high tensiondrums and winches, the step of forming the thermoplastic rod with itsflow-shield sheath is omitted, and the subsequent steps are carried outthe same as taught above and herein except that the thermoplastic rodand its flow-shield sheath are not present nor need their properties beconsidered.

Seventh; while the flowable settable adhesive substance is still liquidand/or semi-liquid (including “flowable”) it is situated upon theoutside surface of the preferably permanently elongated strength member,then a preferably braided sheath is formed about the combination of thepermanently elongated strength member and the flowable settable adhesivesubstance. The temperature of the settable adhesive substance at thetime when it contacts the strength member preferably is less than eighty(80) degrees Centigrade, and also preferably less than 117% Centigrade,and at a temperature that shall not damage the synthetic filamentscontacting the adhesive substance. In other words, the settable adhesivesubstance is situated upon the strength member at temperature that islower than a phase change temperature of fibres forming the strengthmember, and preferably also lower than a phase change temperature offibres forming a braided sheath to be formed about the strength memberas taught in subsequent steps of the disclosed method. Preferably, thestrength member is under a tension that increases the temperature thatfilaments forming the strength member are able to tolerate whensituating upon the strength member the gettable adhesive substance, andsimilarly the braids of the braided sheath are also under such atension. The braid point, braid tension, thickness of the coating,viscosity of the settable substance and lag time can be selected so thatno or minimal flow of the flowable settable adhesive substance to theoutside surface of the braided sheath occurs. Or, the braid point, braidtension, thickness of the coating and lag time may be selected so that aflow of sufficient volume of the settable adhesive substance to theoutside surface of the braided sheath occurs so as to permit smoothingthat portion of the settable adhesive substance that flowed to theoutside surface of the braided sheath into a smooth coating about thebraided sheath. A lag time, also known as a “set time”, of at least 15seconds is preferred, with at least one minute being more preferred,with at least 2 minutes being yet more preferred, with at least 3minutes being even yet more preferred, with at least 4 minutes being yetagain more preferred, with at least 5 minutes being even more preferred,with at least 6 minutes, at least 7 minutes, at least 8 minutes, atleast 9 minutes, at least 10 minutes, at least 11 minutes, at least 12minutes, at least 13 minutes, and least 14 minutes being most preferred,and with up to one hour or even more being useful. Thus, the methodincludes selecting for a lag time any of the above mentioned preferredlag times, with at least 15 seconds being the minimal preferred lagtime.

In order to prepare the outside of the strength member and possibly aswell the inside of the strands converging to form the braided sheath foradhesion via the adhesive substance, electricity preferably is appliedto the surface of preferably the strength member, and possibly also tothe strands forming the braided sheath, at a stage in the productionprocess that is immediately before the deposition of the settableadhesive substance onto the surface of the strength member. This can beaccomplished by Corona treatment (e.g. air plasma method and treatment),or by Atmospheric Plasma method and treatment, Flame Plasma method andtreatment or Chemical Plasma method and treatment. A brush—the term“brush” in this instance as used in electrical energy applications,having a circular dimension through which passes at least the strengthmember is preferred for utilization of the Corona treatment. While ithas been described that this production method embodiment is used whenemploying a flowable, settable adhesive substance, it also can be usedwhen employing production methods including situating upon the outsidesurface of the strength member solid, including powder, phase changeablesubstances capable of causing adherence of the strength member to thesheath.

A presently preferred method includes using a polyurethane blendingmachine (e.g. a mixing machine) having an injection head constructed,designed and configured to situate the desired coating of the flowableadhesive substance about the outside surface of the braided sheath. Thismay be done by configuring the injection head either to spray, extrude abead, or pour a stream. Then, the flowable adhesive substance may besituated onto the outside surface of the strength member by spraying thesettable adhesive substance onto the strength member, or alternativelyby passing the strength member through a bath of such substance, oragain alternatively by pouring such substance directly onto the strengthmember. If direct spraying or pouring is selected, the injection head ispositioned adjacent to the outside surface of a length of the strengthmember. The strength member is fed out from a pay out spool whilesimultaneously being taken up on a take up spool. The braided sheath isformed about the strength member as described using usual methods forforming a braided sheath about a strength member. Preferably, the braidpoint is immediately behind (i.e. downstream of) either the applicationpoint of the flowable adhesive substance onto the strength member'soutside surface, or is immediately downstream of a die that itself isimmediately downstream of the application point of the flowable adhesivesubstance onto the strength member's outside surface, so that thestrands of the braided sheath are pressed into the flowable adhesivesubstance and pressed onto the outside surface of the strength memberprior to and preferably immediately prior to the flowable adhesivesubstance setting (i.e. solidifying), and becoming solid. The flowableadhesive substance in its set, and especially in a solid form, thenoccupies void spaces both between the strands of the braided sheath aswell as between the strands of the braided sheath and the outsidesurface of the strength member, thus sealing off the braided sheath sothat impurities and water cannot pass through the braided sheath to thestrength member. Furthermore, the flowable adhesive substance bothoccupies void spaces between the braided sheath and the outside surfaceof the strength member, while also adhering the braided sheath to thestrength member.

When using the die downstream of the application point of the flowableadhesive substance onto the outside surface of the strength member, thedie is designed, constructed, configured and positioned so as todistribute more or less uniformly about the outside surface of thestrength member the flowable adhesive substance. The surfaces of the dieare selected of a material that shall not hind to the flowable settableadhesive substance. As mentioned supra, the braid point is immediatelydownstream of such die, for the reasons described supra.

The thickness of the layer of the set adhesive substance, i.e. the solidphase of the adhesive substance, at its widest zone between the insidesurface of the braided sheath and the outside surface of the strengthmember, is selected so as to be less than 5% of the overall radius ofthe finished rope, and preferably is less than 4% of such radius, yetpreferably less than 3% of such radius, yet more preferably less than 2%of such radius, yet even more preferably less than 1% of such radius,and yet again even more preferably less than 2 mm in thickness, and evenmore preferably less than 1 mm in thickness, and yet even morepreferably less than 0.5 mm in thickness, and even yet again morepreferably less than 0.25 mm in thickness, and again even morepreferably less than 0.15 mm in thickness.

If the option of selecting the braid point, braid tension, thickness ofthe coating, viscosity of the settable adhesive substance and lag timeso as to cause some of the flowable adhesive substance to be forcedthrough the strands forming the braided sheath to the outside surface ofthe braided sheath is selected, than the coverbraided strength membercan pass through a second die that smoothes the settable adhesivesubstance about the outside surface of the braided sheath. The surfacesof this second die also are of a material selected so as to not adhereto the settable adhesive substance, as are the ambient temperaturesabout the region of the die selected to preclude premature setting ofthe adhesive substance while contacting the die. If it is desired to useheat to set the settable adhesive substance, this step may be done in alinearly shaped oven of about one to fifteen meters in length, or lesserif lesser is sufficient, that the coverbraided strength member is passedthrough prior to being wound up on the take up spool, but after passingthrough the second die if such second die step is selected, with thetake up spool located downstream of as well as external of the oven. Thesecond die preferably is located immediately downstream of the braidpoint.

It is useful for the method of the present disclosure that the flowableadhesive substance is dried, i.e. solid, prior to contacting machineryor portions of machinery other than the dies, and especially prior tothe combination of the strength member, the adhesive substance and thebraided sheath being bent, such as being bent about a wheel, capstan,pulley, winch, block or the like. Furthermore, it is useful that theadhesive substance is set, including dried, prior to contacting objectsother than the strength member and strands of the braided sheath,especially objects that pull upon the outside surface of the braidedsheath. However, if it is not possible to enact such teachings, it isimportant that the set time permit cleaning of the machinery from excessof the settable adhesive substance prior to its setting.

For the settable adhesive substance polyurethane is preferred. Passingthrough the oven, or otherwise in a controlled environment facilitatingsetting of the settable adhesive substance, sufficient heat is appliedin sufficient lack of humidity so as to accelerate adherence of thepolyurethane or other settable adhesive substance to both the outsidesurface of the strength member and also to the inside surface of thebraided sheath, and in some cases to the outside surface of the braidedsheath.

Substances that accelerate the setting into a solid of the polyurethanematerial or other settable adhesive substance, as are conventionallyknown in the art, are selected for use with and in the polyurethaneblending machine. That is, such substances are blended with thepolyurethane or other settable adhesive substance just prior to thesettable adhesive substance being applied to the outside surface of thestrength member.

Additionally, substances that reduce drag and/or increase the elasticityof the settable adhesive substance may be used, as well as substancesthat increase its abrasion tolerance, and resistance to degradation byelements such as light, heat, cold and salt water can be added to theflowable settable adhesive substance prior to its being situated ontothe outside surface of the strength member. Furthermore, substances thataffect its affinity to water, such as silicon or Teflon, or in certainapplications substances that enhance its affinity to water, can beblended with the flowable settable adhesive substance.

The elasticity and/or also an elastomeric substance content of the finaland set phase of the settable adhesive substance is selected so thatsuch set substance does not prematurely crack or separate from theinside surface of the braided sheath or from the outside surface of thestrength member during use, including bending about sheaves and blockssuitable for any particular diameter of the rope. The elasticity for thefinal, set phase of the settable adhesive substance is as taught supraat the temperature range taught supra, and at temperatures exceedingnegative 15 (−15) degrees Centigrade preferably is of from 20% to 550%,or even greater.

It is considered important for maximal strength and longevity of therope of instant disclosure that the strength member itself as well asthe filaments and strands forming the strength member be contacted withan adhesive chemical agent, such as a chemical agent suitable for usewith filaments formed of UHMWPE and LCP. Preferably, prior to the stepof providing the strength member, a step of removing some and preferablyall or nearly all humidity from the strength member followed by a stepof adding the chemical adhesive agent to the strength member isselected. Then, the strength member containing the chemical adhesiveagent is provided, and the settable adhesive substance situated on thestrength member's outside surface prior to the step of braiding thebraided sheath about the strength member. As taught above, the outsidesurface of the strength member preferably includes the chemical adhesiveagent that also is including within the body of the strength member,especially in, about, between and among the filaments and strandsforming the strength member.

As taught above and herein, preferably such chemical adhesive agent hasan elasticity during its set phase that is lesser than the elasticity ofthe set phase of the settable adhesive substance. Furthermore,preferably the set phase of the chemical adhesive agent has a frictionwhen wet with water that is greater than is a friction when wet withwater of the set phase of the settable adhesive substance.

Preferably, the strength member's chemical adhesive agent includes amaterial having a friction when wet with water and especially salt waterthat is a friction sufficient to measurably increase the splice strengthof the strength member.

In one embodiment of the present disclosure that is a presentlypreferred embodiment, the braid angle of the braided sheath is greaterthan the braid angle of the strength member. However, in some cases thebraid angle of the braided sheath may be lesser than, or same as thebraid angle of the strength member.

Preferably, the settable adhesive substance differs from the chemicaladhesive agent, as taught above and herein. However, in someapplications they may be the same or similar, though such applicationsare not preferred.

It is important to the strength and longevity of the synthetic rope ofthe present disclosure that the proportion of the cross sectional areaof the synthetic rope of the instant disclosure that is occupied by thestrength member be at least 40% of the total cross sectional area of therope, and preferably at least 50% of the total cross sectional area ofthe rope, and yet more preferably at least 60%, at least 65%, at least70%, at least 75%, at least 80%, at least 85%, at least 90% and/or atleast 95% of the total cross sectional area of tile rope. This insuresthat when bending over powered blocks, capstans, traction winches,sheaves and the like that a suitable surface area of the outside surfaceof the rope presses upon the strength member so as to not causepremature failure of the settable adhesive substance.

When the strength member of the rope of instant disclosure includes apre-heat stretched strength member, or includes a pre-heat stretchedstrength member having a core shaped so as to support the naturallyoccurring interior shape of the strength member, or further includeswithin the strength member any amount of conductors, whether copper,fibre optic or the like, water and/or electrical shields, and other, itis important to the strength and longevity of the synthetic rope of thepresent disclosure that the proportion of the cross sectional area ofthe synthetic rope of the instant disclosure that is occupied by thecombination of the strength member and anything enveloped by thestrength member be at least 30% of the total cross sectional area of therope and more preferably at least 40% of the total cross sectional areaof the rope, and preferably at least 50% of the total cross sectionalarea of the rope, and yet more preferably at least 60%, at least 65%, atleast 70%, at least 75%, at least 80%, at least 85%, at least 90% and/orat least 95% of the total cross sectional area of the rope. This insuresthat when bending over powered blocks, capstans, traction winches,sheaves and the like that a suitable surface area of the outside surfaceof the rope presses upon the strength member so as to not causepremature failure of the settable adhesive substance,

In a most highly preferred embodiment of the present disclosure, thethickness of the wall of the braided sheath is less than 16 mm (sixteenmillimeters), and better less than 14 mm (fourteen millimeters), betteryet less than 12 mm (twelve millimeters), yet again better less than 10mm (ten millimeters), yet again even more better less than 8 mm (eightmillimeter), and preferably less than 7 mm (seven millimeter), and morepreferably less than 6 mm (six millimeter), and yet more preferably lessthan 5 mm (five millimeter), yet even more preferably less than 4 mm(four millimeter), further preferably less than 3.5 mm (three point fivemillimeter), yet most preferably not more than 3 mm (three millimeter),with approximately from 2 mm (two millimeter) to 3 mm (three millimeter)being preferred, with at least 0.5 mm (half a millimeter) being useful,depending upon the application intended for the synthetic rope of theinstant disclosure.

Preferred Spliced Eye and Sling Fabrication Methods

A preferred method of manufacturing and using the disclosed rope is tomanufacture a section of the disclosed rope with an eye spliced at eachend of the section of disclosed rope. A section of the disclosed ropehaving an eye spliced at each end also is known as a “sling” of thedisclosed rope or as a “spliced eye sling” of the disclosed rope. Theknown art does not teach a suitably strong method for forming splicedeyes in a tightly coverbraided ropes. Following is a presently preferredmethod for forming a spliced eye into each end of a section of thedisclosed rope, i.e. for forming a sling of the disclosed rope. Asection of the disclosed rope with a spliced eye formed into each end ofsuch section, i.e. a sling of the disclosed rope, is most suitable foruse in any of the applications and uses mentioned herein as well as anyother applications and uses.

Preferred Sling Production Method Terminology:

“Strength Member Core” also Means “Strength Member”

Step One: a predetermined length of strength member core is selected(the predetermined length of strength member core hereinafter referredto as the “core rope”). The core rope preferably is a hollow braidedrope. When the core rope is intended for applications including but notlimited to seismic applications, paravane seismic lines, yachting lines,rigging lines, anchoring lines, deep water oil rig mooring lines, towingwarps and trawler towing warps and and any other uses for rope, cable orchain, and also such as when the core rope is made from a UHMWPE, amaximal amount of a suitable impregnation substance included within thestrength member has been found to be advantageous.

Step Two: an eye is spliced at one end of the length o the core rope,and preferably an eye is spliced at both ends of the length of the corerope, forming a core rope sling. The preferred splice method is toinsert the cut end of the core rope into the hollow body of the hollowbraided core rope by opening up the braid of the core rope and passingthe cut end and the part of the core rope intended to form the insertedportion of core rope forming part of the splice braid zone into the bodyof the core rope intended to form the external portion of the core ropeforming part of the splice braid zone, and then either leaving the cutend of the core rope enclosed within the hollow body of the core rope inthe intended splice braid zone or pulling the cut end of the core ropeout of the body of the core rope at a point that is at an end of thesplice braid zone that is farthest from the eye formed by this process.

Step Three: several core rope slings are attached to one another inorder to form a linear element formed of a series of such core ropeslings. The various core rope slings are attached to one another to formsuch linear element by connecting subsequent (and/or intended to besubsequent) core rope slings eye to eye with sections of twine, thetwine forming such sections of twine hereinafter also known as“connecting twine”. An intermediate length of connecting twine is leftin between the interconnected eyes of each subsequent core rope sling sothat such intermediate length of connecting twine is about from fivecentimeters to 200 centimeters in length, or even more, depending uponthe ultimate length of the splice braid zone to be coverbraided. Thisintermediate length of connecting twine equals approximately double thelength of any core rope sling's splice braid zone, or is even aboutdouble such length plus an additional five to twenty centimeters.

Step Four; the interconnected core rope slings are wound upon a reeland/or spool that shall be used with or in conjunction with a feed outspool and/or a feed out wheel of a conventional braiding machinedesigned and configured to form braided sheaths about lengths of ropeand/or other linear elements. Care is taken to impart minimal andpreferably no rotation to the core rope slings so as to avoid impartingtorque to the final finished product. In all cases care is taken toensure that the core rope slings remain torque free, i.e. lacking atendency to rotate about their longitudinal axis when tension is appliedto the core rope sling and/or to the finished product.

Step Five: a length of twine is passed over the take up wheel andaffixed to the take up spool at one end, such length of twinehereinafter also known as the “take up twine”. At another location onthe length of take up twine that corresponds to a location intended forthe braid point the various strands forming the braided sheath, also areattached to the take up twine.

Care is taken to ensure that sufficient length of the take up twineremains upstream of the braid point to permit future knotting andconnecting as is described further below, and that such upstream portionof the take up twine is retained outside of the converging braid strandsin order to preclude it becoming covered by or enclosed within a hollowbraided sheath that is intended to be formed, such withdrawn portion ofthe take up twine also to be known hereinafter as the “withdrawn portionof take up twine”.

Step Six: the operation of the braiding machine is started causing ahollow braided sheath formed of the strands to be formed, if one is tobe formed, such as when forming a braided sheath with the process of thepresent disclosure.

Step Seven: after a predetermined length of the hollow braided sheath isformed, such predetermined length corresponding to about twice thelength of the splice braid zone of any eye of any core rope sling beingused as a strength member core, plus an additional about ten to twentycentimeters to be used for future steps, the braiding machinesoperations are paused.

Step Eight: an eye of a first core rope sling that also is an eyeforming the distal end of the linear element formed of severalinterconnected core rope slings and at least a corresponding splicebraid zone of the same first core rope sling's eye are inserted into theinterior zone of the converging strands forming the hollow braidedsheath, and then the eye is withdrawn from within the interior zone ofthe converging strands forming the hollow braided sheath by passing itthrough the converging strands forming the hollow braided sheathproximal where such strands enter the braid point.

Step Nine: the withdrawn eye is extended and collapsed, i.e. not opened,and is laid alongside the section of hollow braided sheath formed as aresult of the above steps so that the base of the eye, i.e. that portionof the open eye most proximal the splice braid zone, is near the braidpoint, and the furthest portion of the eye from the base of the eye isfurther downstream from the braid point.

Step Ten: The action of the braiding machine is started briefly so as tomake preferably one wrap, and up to two, three or four wraps of thestrands forming the braided sheath about the splice braid zone adjacentthe withdrawn eye, then the action of the braiding machine is againpaused.

Step Eleven: The withdrawn portion of take up twine is passed throughthe withdrawn eye of the first core rope sling and knotted back onitself so as to affix the withdrawn eye of the first core rope sling tothe withdrawn portion of take up twine, thus attaching the withdrawn eyeto the take up wheel thereby allowing to impart traction to thewithdrawn eye and thus to the entire core rope sling and any other corerope slings connected to it.

Step Twelve: the hollow braided sheath is severed just upstream of thepoint where the withdrawn length of twine attaches to the hollow braidedsheath.

Step Thirteen: While the braiding action of the braiding machine isretained as paused, the take up spool is energized so as to advancedownstream the hollow braided sheath and the braid point, thustightening the withdrawn portion of take up twine connecting the hollowbraided sheath and the withdrawn eye.

Step Fourteen: the upstream severed length of hollow braided sheath isnow bent back (i.e. “doubled back”) and passed through the withdrawn eyeand then passed into the interior zone of the converging strands formingthe hollow braided sheath and then laid alongside the splice braid zonecorresponding to the withdrawn eye.

Step Fifteen: the take up wheel is now, if necessary, reversed from itstake up direction to a pay out direction so as to cause the braidtension to become reduced and also so as to cause the braid angle tobecome more obtuse, until the braid angle is nearer to eighty-ninedegrees than it is to seventy degrees when measured between the braidring and a converging strand used in forming the hollow braided sheath,with a braid angle of about eighty to eighty-seven degrees being alsouseful, with the result that the core rope sling's material is notvisible to an unaided eye after the braided sheath has been formed aboutthe splice braid zone of the core rope sling.

Step Sixteen: the action of the braiding machine is then commencedagain, including that the take up spool again commences to rotate in a“take up” direction, causing the braided sheath to form about the splicebraid zone corresponding to the withdrawn eye.

Step Seventeen: when the braid point is proximal the point of the splicebraid zone that is furthest from the withdrawn eye, the action of thebraiding machine is again paused.

Step Eighteen: the take up spool is advanced while the action of thebraiding machine remains paused, so as to increase the braid tension andalso so as to create a less obtuse (i.e. more acute) braid angle, withthe result that the core rope sling's material is not visible after thebraided sheath has been formed about a portion of the core rope slingnot having a splice braid zone.

Step Nineteen: the action of the braiding machine is again started andcontinued to operate so as to cause the braided sheath to form about thelength of core rope sling up to the point that a portion of the nextsplice braid zone arrives at the braid point.

Step Twenty: the action of the braiding machine is again paused, and thetake up spool is again reversed, again reducing the braid tension andagain causing the braid angle to become more obtuse, again so as toachieve the result that no portion of the material forming the core ropesling is visible to the unaided eye after the braided sheath has beenformed about the splice braid zone of the core rope sling.

Step Twenty-One: a “removable void spacer” is provided. The void spacermay have its terminal ends bent at ninety degrees or otherwise notparallel to the axis of the main length of the void spacer, with suchterminal ends' long dimensions preferably both aimed in a similarorientation. A preferable removable void spacer is formed of a hollowsteel tube such as a hollow steel pipe having a steel eye welded at oneend of the pipe and having a high quality steel cable of suitablediameter doubled over and inserted into the other end of the steel pipeand held in place by solidifying a molten bead weld inside the end ofthe pipe. The result of such a construction method for a removable voidspacer is a removable void spacer designed and configured so as toresult in a hollow steel pipe having a loop of high grade steel wireprotruding at one end and having a steel eye affixed to its other end,such as may be a link of steel chain welded to such other end of thehollow steel pipe. Such preferable removable void spacer shall be knownas “the preferred removable void spacer”.).

Step Twenty-Two: a preferred void spacer is situated alongside thesplice braid zone that is most proximal the braid point in such afashion that the steel eye of the preferred void spacer as well as somelength of the steel pipe of the preferred void spacer is lying alongsidethe braided sheath while the majority of the preferred void spacer'ssteel pipe is lying alongside the core rope sling's still uncoveredsplice braid zone in such a fashion that the steel pipe ends and thesteel wire loop commences where the exposed splice braid zone meets itsopen spliced eye. To effectively so position the preferred void spacer,it is needed to first insert the preferred void spacer into the interiorzone of the converging braid strands, and then to withdraw that portionof it that is to lie alongside the braided sheath by passing the steeleye of the preferred void spacer through the converging strands formingthe braided sheath proximal where such strands enter the braid point.Step Twenty-Three: the take up wheel is now again reversed from its takeup direction to rather a pay out direction so as to cause the braidtension to become reduced and also so as to cause the braid angle tobecome more obtuse, until the braid angle is nearer to eighty-ninedegrees than it is to seventy degrees when measured between the braidring and a converging strand used in forming the hollow braided sheath,with a braid angle of about eighty to eighty-seven degrees being alsouseful, with the result that the core rope sling's material is notvisible to an unaided eye after the braided sheath has been formed aboutthe splice braid zone of the core rope sling.

Step Twenty-Four: the action of the braiding machine is then commencedagain, causing the braided sheath to form about the splice braid zone.

Step Twenty-Five: the action of the braiding machine is again commencedincluding that the take up spool again commences to rotate in a “takeup” direction until the braided sheath is formed to about the locationwhere the splice braid zone meets its open eye.

Step Twenty-Six: The braiding machine's operations are again paused.

Step Twenty-Seven: a connecting line connecting the two open eyes mostproximal the braiding point is severed, and that open eye having itssplice braid already covered by the braided sheath is withdrawn fromwithin the interior zone of the converging braid strands in a similarmanner as described supra for withdrawing an open eye from within suchinterior zone of converging braid strands, and the other eye is retainedon a hook that is provided underneath the braid point.

Step Twenty-Eight: The braiding machines action is again started so asto cause more hollow braided sheath to be formed downstream of thewithdrawn eye, the length of hollow braided sheath to be formed againcorresponding to about two times the length of the splice braid zonespresent on the core rope slings plus an additional about twentycentimeters of length.

Step Twenty-Nine: when about half the intended overall length of thehollow braided sheath being formed in the above step is completelyformed, the braiding machine is again paused and a section of twine isattached at the braid point to the strands forming the hollow braidedsheath, said section of twine being about twice the length of a splicebraid zone to be coverbraided, and said section of twine being retainedoutside of the converging braid strands. This section of twine ishereinafter also known as the “next eye connecting twine”. Step Thirty:the braiding machine is again started and operated until the intendedlength of the hollow braided sheath is formed.

Step Thirty-One: The eye of the core rope sling that has been retainedon a hook underneath the braid point is now inserted into the interiorzone of the converging braid strands, and then withdrawing from suchinterior zone of converging braid strands in the fashion as describedabove for withdrawing eyes from such interior zone of converging braidstrands, while the splice braid zone corresponding to this eye isretained within the interior zone of the converging braid strands sothat it can be coverbraided. This eye is then attached to the next eyeconnecting twine.

Step Thirty-Two: The length of hollow braided sheath is severed about inhalf.

Step Thirty-Three: While the braiding action of the braiding machine isretained as paused, the take up spool is energized so as to advancedownstream the hollow braided sheath and the braid point, thustightening the eye connecting twine that connects the hollow braidedsheath and the withdrawn eye.

Step Thirty-Four: the downstream severed end of the braided sheath isinserted into the open portion of the steel wire loop forming theterminal end of that void spacer nearest the end of that eye alreadyhaving had its splice braid zone coverbraided and also having thepreferred void spacer situated proximal its splice braid zone. Thesevered end may be frayed prior to being so inserted. Then the severedend is bend back, that is doubled over the steel wire loop, and held inplace by hand by being squeezed together with the other portion of thehollow braided sheath near the steel wire loop. The severed ends may bewrapped tightly with tape and then cut into a spiked, tapered shape tofacilitate such insertion and retention.

Step Thirty-Five: the preferred void spacer is pulled out (i.e. iswithdrawing) from between the sheath and the core rope, in a directionthat draws the severed end of the braided sheath into within the braidedsheath and causes it to occupy a position between the braided sheath andthe core rope's splice braid zone that previously was occupied by thepreferred void spacer. A hydraulic or pneumatic ram is useful for sowithdrawing the preferred void spacer. Optionally, a lubricant may beadded to assist in drawing the severed hollow braided sheath intoposition. Such lubricant also may be used to lubricate the preferredvoid spacer prior to its use. Such lubricant is especially useful shouldthe braided sheath be formed of highly inelastic materials such asUHMWPE and others. This step may be made either when the portion ofsplice braid zone with the preferred void spacer is upstream of ordownstream of the take up wheel, so long as tension is maintained on thecoverbraided core rope sling so as to permit withdrawing the preferredvoid spacer. The take up wheel may be cushioned or padded to permit thepreferred void spacer to pass over it under tension without damagingeither the product being formed of the machinery.

To produce further and subsequent spliced eye slings of the rope of thepresent disclosure, the actions, steps, methods and processes describedin Steps Fourteen and onward are now repeated in the order and sequenceas described hereinabove in order to produce the next spliced eye slingof the rope of the present disclosure. Then, the Steps Fourteen andonward may again be repeated, each time they are repeated another slingof the rope of the present disclosure being formed, until the linearelement formed from the interconnected core rope slings is consumed.Then, Steps One and onward are repeated in order to form more slings ofthe rope of the present disclosure as desired.

Preferably, prior to splicing the eyes into any section of core rope soas to form a core rope sling, a very abrasion resistant, very durablesheath is slid upon the core rope and maintained in a regioncorresponding to any intended open eye to be formed, thereby resultingin a sheathed eye. The best construction for such a sheath is a hollowbraided construction that has been made rigid by use adhesives and byforming a hollow braid of very tight wraps about a rod or rope that isthen removed from such hollow braid where such rope or rope has adiameter that is sufficiently larger than the diameter of the core ropeto be sheathed so that it is not difficult to pass the body of the corerope into the sheath. The rigidity imparted to any eye by such sheathgreatly facilitates handling of the eyes in the production process ofthe present disclosure, and also greatly increases longevity of thespliced eye.

It is important that the braid angle and the elasticity of fibersforming both the braided sheath and forming the strength member ofeither the rope of the present disclosure or of the spliced eye slingsof the rope of the present disclosure, or of any other rope or of anyother sling of the present disclosure, are selected so that the braidedsheath and the strength member core or their equivalents both experiencetotal failure at the same elongation of the final produced rope or itscounterparts. For example, when less elastic fibers form the braidedsheath, and more elastic fibers form the strength member core rope, thestrength member core rope's strands are of a less obtuse braid anglethan are the strands forming the braided sheath.

Further Preferred Fabrication Methods

When the rope of the present disclosure is to be used with high tensionpowered blocks, it is advantageous to have the disclosed thermoplasticcore within the rope of the present disclosure. In such instances ofhaving the thermoplastic core within the rope of the present disclosure,that portion of the thermoplastic core corresponding to those portionsof the core rope of the present disclosure to be used in forming thesplice braid zone and optionally as well any open eye preferably isremoved prior to the splice being formed. Then, the core rope slinghaving the thermoplastic core is coverbraided so as to form a tightlycoverbraided spliced eye sling having a thermoplastic core. It is to benoted that the thermoplastic core is itself contained within a sheaththe stops molten and especially semi liquid phases of the thermoplasticcore from exiting the rope during extreme pressure. A preferredproduction process of the present disclosure for producing ultra highstrength light weight ultra compacted spliced coverbraided rope slingsof the present disclosure is as follows:

First: a thermoplastic core is provided, with or without lead inside thecore for weight, and with or without inside the core insulatedconductors designed and configured to tolerate being permanentlystretched as needed to survive the production process now beingdisclosed, Polyethylene is a good material for most thermoplastic coresfor this process.

Second: the thermoplastic core is enclosed within a sheath that is ableto stop molten phases of the thermoplastic core from exiting the sheathor that is able to mainly stop molten phases of the thermoplastic corefrom exiting the sheath. Such a sheath can be formed of very densely andtightly braided polyester fibers or other fibers having a highersoftening point than the softening point of the thermoplastic core.Third: a strength member is formed about the combination of thethermoplastic core and the sheath enclosing the thermoplastic core.Preferred materials for forming the strength member are fibers formed ofmaterials that are able to be creeped. For example, fibers of UHMWPE,such as Dyneema®. Creeped as used in this disclosure means that thefibers are able to be permanently elongated a certain percentage oftheir initial length under a certain tension and at a certaintemperature, especially a temperature just lower than a phase changetemperature of the material forming the fibers, without compromising thefibers integrity and long term usefulness, and preferably also withoutcompromising the fibers strength. A preferred construction for formingthe strength member is a braided construction and especially a hollowbraided construction.

Fourth: an eye is spliced into one or both ends of the strength member,with a portion of the thermoplastic core corresponding to any intendedsplice braid zone being removed from the intended splice braid zoneprior to completion of the splicing process and the sheath enclosing thethermoplastic core being tied off and knotted so as to become sealed,rather than left cut open, thereby stopping flow of future molten phasesof the thermoplastic core from exiting the sheath. The result is analternative core rope sling.

Fifth: the alternative core rope sling is transformed into analternative coverbraided spliced eye sling using the process of thepresent disclosure for forming spliced eye slings of the presentdisclosure. A preferred material for forming strands forming thecoverbraid is a material such as Dyneema or other UHMWPE. A settableadhesive substance, or a substance capable of being phase changed intoan adhesive substance, where such adhesive substances have an elasticityas taught herein for a settable adhesive substance, including anelasticity of at least 10% at between zero degrees centigrade andnegative fifteen degrees centigrade, and more preferably an elasticityof at least 50% at such temperatures, and more preferably an elasticityup to and even exceeding 550% at such temperatures and at temperaturesthat exceed sixty degrees centigrade preferably is situated about theoutside of the strength member core, i.e, about the outside of thealternative core rope sling, just prior to the convergence of strandsforming the coverbraided sheath about the outside of the alternativecore rope sling. That is, just prior to the formation of any sheathabout the alternative core rope sling. However, care is taken to notsituate the settable adhesive substance or its equivalent about thoseportions of the strength member and/or core rope sling corresponding theany splice braid zone, and the method of the present disclosure includesa step of preventing the settable adhesive substance and/or the secondsynthetic portion from being formed about portions of the strengthmember and/or core rope sling that correspond to a splice braid zone.

Sixth: excess of such adhesive substances are removed from the outsideof the braided sheath.

Seventh: the alternative coverbraided spliced eye sling formed in theabove step and of the combination of the alternative strength member andthe sheath enclosed thermoplastic core are next subject to a tensionthat preferably is lesser than 50% of the break strength of thealternative strength member, and more preferably is less than 30% ofsuch break strength, and yet more preferably is less than 20% of suchbreak strength, and yet more preferably is less than 15% of such breakstrength, and yet again more preferably is less than 10% of such breakstrength, and even yet again is more preferably less than 7% of suchbreak strength, even more preferably is less than 5% of such breakstrength, with about 3% of such break strength being preferred and withlesser than 3% being useful

Eighth: The combination of the tensioned alternative strength member andthe sheath enclosed thermoplastic core are next subjected to a heat thatis regulated and applied in such a fashion so as to cause all or atleast the majority of the fibers forming the strength member core toapproach near to, but to remain at lower than, their phase changetemperature, while simultaneously causing the thermoplastic core tochange to a molten phase. It is worth noting that the disclosed steps offirst applying the disclosed tension to the alternative strength member,whether or not it is already used in forming either or both thealternative core rope sling or the alternative coverbraided spliced eyesling, and then subsequently applying the disclosed heat to at least thealternative strength member, again whether or not it is already used informing either or both the alternative core rope sling or thealternative coverbraided spliced eye sling, is contrary to the trend inthe industry and against the state of the art, and has been found tosurprisingly result in a stronger rope of the present disclosure.

Ninth: the tension and temperature are maintained until a desired amountof elongation of the strength member core can be detected, andpreferably until it is detected.

Tenth: While the tension is maintained on the strength member, whetheror not it is already used in forming either or both the alternative corerope sling or the alternative coverbraided spliced eye sling, and thusby extension also on the sheath enclosed thermoplastic core as well ason anything enclosed within the alternative strength member, thecombination of any or all of the alternative coverbraided spliced eyesling; the alternative strength member and the sheath enclosedthermoplastic core and anything else contained within the strengthmember is cooled until the thermoplastic core has reach a solid phase,resulting in a high strength light weight synthetic rope sling usefulfor all the above mentioned uses.

Preferably, prior to splicing the eyes into the alternative core rope inorder to form the alternative core rope sling, the above mentioned veryabrasion resistant, very durable sheath is slid upon the alternativecore rope and maintained in a region corresponding to any intended openeye to be formed, thereby resulting in a sheathed eye. As taught above,the rigidity imparted to any eye by such sheath greatly facilitateshandling of the eyes in the production process of the presentdisclosure, and also greatly increases longevity of the spliced eye.

INDUSTRIAL APPLICABILITY

A rope may be formed by use of the teachings of the present disclosurewhere such rope's intended use does not necessitate that the rope eitherrequire tolerating the compressive forces generated on high tensionwinches and drums, nor necessitate that the rope exhibit the preferredrope elasticity and/or elasticity to break point values as taughtherein. In such embodiments, a strength member is formed and thesubsequent steps are carried out the same as taught above and herein.

Although the present disclosure has been described in terms of thepresently preferred embodiment, it is to be understood that suchdisclosure is purely illustrative and is not to be interpreted aslimiting. Consequently, without departing from the spirit and scope ofthe disclosure, various alterations, modifications and/or alternativeapplications of the disclosure are, no doubt, able to be understood bythose ordinarily skilled in the art upon having read the precedingdisclosure. Accordingly, it is intended that the following claims beinterpreted as encompassing all alterations, modifications oralternative applications as fall within the true spirit and scope of thedisclosure.

1-50. (canceled)
 51. A process for forming a mainly synthetic rope (1)formed of at least a strength member (7), the process including steps offorming the strength member (7) with a braided construction and fromfilaments including filaments that are able to be creeped, the processcomprising steps of: a) first, applying tension to at least the strengthmember (7); b) second, after applying tension to at least the strengthmember, maintaining tension on at least the strength member; c)subsequently, while maintaining tension on at least the strength member,applying a heat to at least the strength member; d) selecting acombination of the tension and the heat for step (c) so as to causecreep of those filaments of the strength member that are the filamentsthat are able to be creeped, e) detecting a desired amount of elongationof at least the strength member; and f) while maintaining tension on atleast the strength member, cooling the strength member.
 52. The processof claim 51 further comprising steps of cooling the strength memberwhile selecting a sufficient tension for the step of maintaining atension on the strength member during the cooling process so as toresult in permanent elongation of the strength member.
 53. The processof claim 52 wherein the process further comprises selecting for thedesired amount of elongation of the strength member an amount ofelongation that results in the strength member having a lesser diameterthan it had prior to the strength member being permanently elongated.54. The process of claim 53 wherein the process further comprisesselecting for the desired amount of elongation of the strength member anamount of elongation that results in the strength member having agreater compactness than it had prior to the strength member beingpermanently elongated.
 55. The process of claim 52 further comprisingsteps of cooling the strength member while selecting a sufficienttension for the step of maintaining a sufficient tension on the strengthmember during the cooling process so as to result in permanentelongation of filaments forming the strength member.
 56. The process ofclaim 53 further comprising steps of cooling the strength member whileselecting a sufficient tension for the step of maintaining a sufficienttension on the strength member during the cooling process so as toresult in permanent elongation of filaments forming the strength member.57. The process of claim 54 further comprising steps of cooling thestrength member while selecting a sufficient tension for the step ofmaintaining a sufficient tension on the strength member during thecooling process so as to result in permanent elongation of filamentsforming the strength member.
 58. The process of claim 51 wherein theprocess further comprises using capstans turning at varying speeds toapply tension to the strength member.
 59. The process of claim 52wherein the process further comprises using capstans turning at varyingspeeds to apply tension to the strength member.
 60. The process of claim53 wherein the process further comprises using capstans turning atvarying speeds to apply tension to the strength member.
 61. The processof claim 54 wherein the process further comprises using capstans turningat varying speeds to apply tension to the strength member.
 62. Theprocess of claim 55 wherein the process further comprises using capstansturning at varying speeds to apply tension to the strength member. 63.The process of claim 56 wherein the process further comprises usingcapstans turning at varying speeds to apply tension to the strengthmember.
 64. The process of claim 57 wherein the process furthercomprises using capstans turning at varying speeds to apply tension tothe strength member.
 65. The process of claim 51 wherein the tension ofsteps (a) to (c) is lesser than 50 percent of the ropes breakingstrength measured at room temperature.
 66. The process of claim 52wherein the tension of steps (a) to (c) is lesser than 50 percent of theropes breaking strength measured at room temperature.
 67. The process ofclaim 53 wherein the tension of steps (a) to (c) is lesser than 50percent of the ropes breaking strength measured at room temperature. 68.The process of claim 52 further characterized by forming a braidedsheath (8) about the strength member.
 69. The process of claim 68further characterized by forming the braided sheath (8) with a braidangle that is more acute than a braid angle forming the strength member(7).
 70. The process of claim 53 further characterized by forming abraided sheath (8) about the strength member and by forming the braidedsheath (8) with a braid angle that is more acute than a braid angleforming the strength member (7).